2002 Toyota Tundra Body & structure Problems

Excessive frame corrosion and corrosion holes involving even rear subframe

NHTSA ID

11705338

Incident

Nov 15, 2025

Frame needs replacement

NHTSA ID

11695290

Incident

Oct 16, 2025

The contact owns a 2002 Toyota Tundra. The contact, who is an independent mechanic, stated that the fuel tank had detached. The contact stated that the subframe was extremely rusted. There were no warning lights illuminated. The contact stated that the failure was related to NHTSA Campaign Number: 09V444000 (Structure). The contact called the local dealer, but the vehicle was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 190,000.

NHTSA ID

11640935

Incident

Feb 5, 2025

Mileage

190,000 mi

The contact owns a 2002 Toyota Tundra. The contact stated that the frame and the front bumper were severely rusted. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 117,000.

NHTSA ID

11624704

Incident

Nov 12, 2024

Mileage

117,000 mi

The contact owns a 2002 Toyota Tundra. The contact stated that after taking the vehicle to be checked for corrosion to the subframe, the contact was advised that there was significant corrosion on the subframe and the supports underneath the truck bed. The contact was informed that the vehicle was unsafe to drive with any type of load in the truck bed. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 180,000.

NHTSA ID

11589647

Incident

Mar 20, 2024

Mileage

180,000 mi

I was doing maintenance on front and lifted splash guard for access to bolt. On top of the frame, near the firewall, was severe rust. It looks as if the frame could crack at any time. If this happened in highway speed or in traffic, severe risk of injuries. These are known to have issues in salt states (had recalls) and I thought I checked it pretty good before buying. I think this may be from the air conditioning drain system.

NHTSA ID

11582138

Incident

Apr 9, 2024

The contact owns 2002 Toyota Tundra. The contact stated that upon taking the vehicle to an independent mechanic for an oil change and tire rotation, she was informed that the subframe was severely corroded, and the vehicle was unsafe to be driven. The dealer and the manufacturer were not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 250,000.

NHTSA ID

11569273

Incident

Jan 1, 2024

Mileage

250,000 mi

The contact owns a 2002 Toyota Tundra. The contact stated that while the vehicle was in for routine maintenance, the mechanic discovered severe rusting and corrosion on the subframe of the vehicle. The vehicle was taken to the local dealer who determined that the vehicle was unsafe to drive due to the severe rusting of the subframe. The contact was informed that the subframe needed to be replaced. The vehicle was not yet repaired. The manufacturer was not yet notified of the failure. The failure mileage was 200,000.

NHTSA ID

11565735

Incident

Jan 16, 2024

Mileage

200,000 mi

The contact owns a 2011 Dodge Durango. The contact stated that there was severe corrosion on the entire under carriage and subframe and struts. The contact received notification of NHTSA Campaign Number: 09V444000 (Structure) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The failure mileage was unknown. Parts distribution disconnect.

NHTSA ID

11480227

Incident

Nov 18, 2009

The contact owns a 2002 Toyota Tundra. The contact stated that he previously received notification of NHTSA Campaign Number: 09V444000 (Structure). The vehicle was taken to the local dealer and repaired under the recall. Recently, the contact was informed by an independent mechanic that cracks had formed on the rear suspension due to severe corrosion. The contact then took the vehicle to another dealer, Kelly Toyota of Hamburg (1 Industrial Dr, Hamburg, PA 19526), and was informed that the recall was a one-time free repair and the dealer offered no additional assistance. The manufacturer was notified of the failure and informed him that the recall was too old. The vehicle was not repaired. The failure mileage was 81,324.

NHTSA ID

11468602

Incident

Jun 6, 2022

Mileage

81,324 mi

The contact owns a 2002 Toyota Tundra. The contact stated that there were holes in the subframe of the vehicle. The local dealer was contacted and informed the contact that the subframe was not treated with rust inhibitor. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the dealer was not able to spray the rust inhibitor on the vehicle due to Iowa not being a cold state. The approximate failure mileage was 134,000.

NHTSA ID

11434177

Incident

Sep 10, 2021

Mileage

134,000 mi

The frame on the truck is rusted out with holes through it and the metal is rusted out along the entire frame. The truck vibrates when driving and when inspected by the dealer, Kari Toyota, they advised it is unsafe to drive as the frame could break entirely and cause an accident. Report is attached. Toyota was contacted on several occasions by Kari Toyota and myself in May and June of 2021. I had the vehicle in for repair of the frame rust issue on June 15, 2012 but clearly the work was not done properly as the rust issue continued until the vehicle is now undriveable. The vehicle has only 106,681 miles which is low for a typical Toyota vehicle. Toyota refuses to repair the vehicle even though I had followed up on my end by bringing it in for the recall repair. I requested a letter from Toyota explaining why they won't cover the repairs and they refused to send one.

NHTSA ID

11430394

Incident

May 10, 2021

First the gas tank let loose and fell half way off. Result was a new gas tank installed. then part of the frame rusted from the cab. This resulted in having to have it welded. Have had several service repair lights come on that resulted in more fixes. Today just about does it. The spare tire fell to the road because rust ate through what was holding it up. I have all the papers that show the repairs and what it has cost me. I have not done anything yet about spare tire. I have had the truck since 2013 and it has less then 94k miles on it. It had 35 when I bought it and I knew nothing about the rust problem recall. I certainly believe I should have a new frame or some kind of compensation. Over the years I have talked to several dealers that got me no where. I guess this is my last shot.

NHTSA ID

11422830

Incident

Jun 29, 2021

RUST PROBLEM IN FRAME AND REAR CROSSMEMBER

NHTSA ID

11376881

Incident

Sep 9, 2020

TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. THE CONTACT STATED THAT THE FRAME WAS RUSTED AND THERE WAS A HOLE BEHIND THE DRIVER'S SIDE DOOR. THE CONTACT CALLED ACTON TOYOTA OF LITTLETON (221 GREAT RD, LITTLETON, MA 01460, (978) 263-1500) HOWEVER, THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE CONTACT STATED THE FAILURE WAS LIKE NHTSA CAMPAIGN NUMBER: 09V444000 (STRUCTURE). THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 220,000.

NHTSA ID

11353977

Incident

Sep 1, 2020

Mileage

220,000 mi

FRAME IS SEVERELY RUSTED AND CALLED ABOUT A PREVIOUS RECALL TO REPLACE THE FRAME BUT THEY TOLD ME THAT I HAD JUST MISSED IT AND THE RECALL HAD ENDED? I TOLD THEM THAT I HAD THE TRUCK AT THE TIME OF THE RECALL BUT WAS NEVER NOTIFIED OF THE RECALL. I HAD RECEIVED OTHER PROMOTIONS ABOUT NEW VEHICLE DISCOUNTS FOR TOYOTA OWNERS, BUT NEVER ABOUT ANY RECALL ON THE TRUCK AT ALL? NOW THE FRAME IS RUSTED EVEN WORSE BUT I HAVE TO CONTINUE TO DRIVE THE TRUCK BECAUSE I CANNOT AFFORD ANOTHER VEHICLE AT THIS TIME! THE OTHER DAY I PULLED INTO MY DRIVEWAY AND NOTICED THE VEHICLE MAKING A NOISE AND WHEN I LOOKED UNDER THE VEHICLE, THE FUEL TANK STRAP HAD RUSTED AND FELL APART AND THE FUEL TANK WAS HANGING DOWN. I HAD TO TAKE A RATCHET STRAP AND STRAP THE FUEL TANK BACK UP TO THE FRAME BECAUSE I HAVE TO HAVE THE TRUCK TO DRIVE TO WORK. I LOOK NOW AND THERE IS A RECALL ABOUT THE CORROSION ON THE FUEL TANK STRAPS AND ON THE SPARE TIRE CARRIER AND SUCH AND YET AGAIN I WAS NOT NOTIFIED ABOUT THE RECALL. HAD THE FUEL TANK NOT FELL OUT ON ME AND THEN ME LOOK ON YOUR SITE TO FIND OUT ABOUT IT, I WOULD AGAIN NOT HAVE KNOWN THERE EVEN WAS A RECALL UNTIL IT WAS TOO LATE TO DO ANYTHING ABOUT IT ! I NEED TO KNOW WHAT CAN BE DONE ABOUT GETTING TOYOTA TO HONOR THE FRAME REPLACEMENT RECALL ON MY TRUCK THAT I WAS NEVER NOTIFIED ABOUT EVEN THOUGH I KNOW THAT THEY KNEW I OWNED IT BECAUSE OF THE OTHER MAIL THEY HAD SENT ME ABOUT NEW VEHICLE OFFERS FOR CURRENT TOYOTA OWNERS? ANY AND ALL HELP APPRECIATED AS I CANNOT AFFORD TO BUY ANOTHER TRUCK HAVING SO MUCH MONEY IN THIS ONE THAT IS EVENTUALLY GOING TO BREAK IN HALF AS I DRIVE IT DOWN THE ROAD WHICH IS NOT SAFE FOR ME OR ANYONE ELSE ON THE ROAD AROUND ME. I LIVE IN KENTUCKY WHERE IS ONE OF THE PRIMARY AREAS FOR SALT. THANK YOU, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

11283118

Incident

Nov 27, 2019

Mileage

344,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR MAINTENANCE, THE CONTACT WAS INFORMED THAT THE REAR CROSS MEMBERS ON BOTH SIDES AND THE FRAME WERE SEVERELY CORRODED AND NEEDED REPLACEMENT. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 86,000.

NHTSA ID

11277359

Incident

Oct 24, 2019

Mileage

86,000 mi

FRAME IS RUSTED AND WON'T PASS INSPECTION. HAVE ALREADY REPLACED FENDER AND BOX

NHTSA ID

11265779

Incident

Oct 2, 2019

"TOYOTA RECALLS" CHASIS/FRAME - I HAD EVERY RECALL OR SERVICE BULLETIN COMPLETED BY TOYOTA SALES/SERVICE IN OUR AREA. TOYOTA'S FIX FOR THE FRAME RUST DID NOT WORK. I WAS INFORMED THIS WEEK THAT THERE ARE NOW HOLES IN THE FRAME. THE TAILGATE IS RUSTING ALONG WITH THE BED OF THE TRUCK AS I WAS ABLE TO SEE THE UNDERNEATH OF THE BED WHEN THE TOYOTA DEALERSHIP PUT IT UP ON THE HOSIT YESTERDAY. THIS TRUCK HAS BEEN MAINTAINED PROPERLY, HAS APPROXIMATELY 135,000 MILES ON IT, AND THE BODY IS STILL IN GOOD CONDITION. ALTHOUGH I WAS NOTIFIED THIS WEEK ABOUT THE FRAME, IT'S HAS BEEN ON GOING FOR SOME TIME AND I DO NOT UNDERSTAND WHY NO ONE IN THE LAST 2 YEARS INFORMED US OF THE FRAME RUST DAMAGE. EVEN THE TOYOTA SERVICE DEPARTMENT THAT HAD SERVICED THE VEHICLE EARLIER THIS YEAR DID NOT INFORM ME OF THE EXTENT OF FRAME RUST DAMAGE.

NHTSA ID

11256652

Incident

Sep 17, 2019

Mileage

135,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. UPON INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE REAR DIFFERENTIAL WAS LEAKING. THE CONTACT ALSO MENTIONED THAT THE CHAIN THAT HELD THE SPARE TIRE IN PLACE FRACTURED FROM THE FRAME. THE VEHICLE WAS TAKEN TO BROWN'S TOYOTA OF GLEN BURNIE (7167 RITCHIE HWY, GLEN BURNIE, MD 21061 (410) 761-9000) WHERE THE CONTACT WAS INFORMED THAT THE REAR AXLE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 81,000.

NHTSA ID

11253378

Incident

Aug 19, 2019

Mileage

81,000 mi

2002 TOYOTA TUNDRA SR5 FRAME WAS SPRAYED WITH UNDERCOATING PER RECALL WHEN IT SHOULD HAVE BEEN REPLACED. NOW FRAME HAS HOLES 1" WIDE 4" LONG BEHIND FRONT TIRES ON BOTH SIDES. BODY STILL LOOKS NEW. I SEE TRUCKS FOR SALE THAT ARE RUSTED OUT BEYOND REPAIR BUT HAVE NEW FRAMES.

NHTSA ID

11240650

Incident

Jul 25, 2019

Mileage

178,000 mi

TL* THE CONTACT OWNS A 2002 TOYOTA TUNDRA. THE CONTACT STATED THAT THERE WAS EXTENSIVE RUST AND CORROSION PERTAINING TO THE FRAME. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 09V444000 (STRUCTURE) AND 05V225000 (SUSPENSION). THE CONTACT WAS UNCERTAIN IF THE FAILURES WERE RELATED TO THE RECALL CAMPAIGNS. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES AND INDICATED THAT THE BUY BACK OPTION AND FRAME REPLACEMENT EXTENDED CAMPAIGN ENDED IN 2012 AND THERE WAS NO REMEDY. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11228686

Incident

Feb 1, 2018

I PURCHASED THIS TRUCK USED IN 2015 AND WAS UNAWARE OF ANY RECALLS DUE TO FRAME RUST. I HAVE REPLACED TAILPIPE, MUFFLER, MANY BRAKE COMPONENTS DUE TO RUST PROBLEMS. THE FRAME NOW RUSTED MORE AND I AM BEING TOLD THAT IT MAY BE UNSAFE TO DRIVE. A MECHANIC TOLD ME ABOUT THIS FRAME RUST RECALL AND I TOOK IT TO FRED ANDERSON TOYOTA IN RALEIGH,NC. THE FOUND THAT ALL RECALL ITEMS HAD BEEN COMPLETED BY THE DEALER IN BOONE,NC. I FIND THIS HARD TO BELIEVE SINCE THE RUSTING ISSUE IS MUCH MORE SEVERE. I JUST WANT A FAIR EVALUATION OF WHAT CAN OR SHOULD BE DONE. FRED ANDERSON TOYOTA IN RALEIGH DID HAVE THE TRUCK BUT NOT SURE HOW FAR THEY TOOK THE INVESTIGATION OF RUST.

NHTSA ID

11221841

Incident

Jun 17, 2019

THE CHASSIS OF THE TRUCK IS VERY DAMAGED BY RUST, IN SOME PARTS IT EVEN HAS HOLES, SO I DO NOT KNOW IF IT IS VERY SAFE TO HANDLE IT. I BOUGHT IT AT A CAR DEALER A FEW WEEKS AGO, I THOUGHT IT WAS JUST A BIT OF RUST ... BUT WHEN I CHECKED IT OUT BETTER I NOW FIND THAT THE RUST REALLY HARMS THE STRUCTURE, ANOTHER PROBLEM ... IT GIVES OFF A STRONG SMELL OF GASOLINE. ..

NHTSA ID

11221293

Incident

Jun 7, 2019

Mileage

174,000 mi

FRAME OF TRUCK WAS TOTALLY RUSTED OUT AND VEHICLE WAS CONSIDERED "NON-DRIVABLE", BY TOYOTA DEALERSHIP. TOYOTA DEALERSHIP "CHECKED" THE FRAME IN 2011 AND SAID IT WAS "FINE" AND WE HAVE ONLY DRIVEN THE TRUCK 40,000 MILES SINCE. THEY SAID TO SALVAGE THE TRUCK BUT IT ONLY HAS 127,000 MILES ON IT!!!! CASE #[XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TT

NHTSA ID

11210461

Incident

May 28, 2019

Mileage

127,000 mi